A.O. Smith GCV Series Service Handbook
  1. Manuals
  2. Brands
  3. A.O. Smith Manuals
  4. Water Heater
  5. GCV Series
  6. Service handbook

A.O. Smith GCV Series Service Handbook

Standard residential fvir gas water heaters
Hide thumbs
Table of Contents

Advertisement

Quick Links

http://waterheatertimer.org/How-to-troubleshoot-gas-water-heater.html
SERVICE HANDBOOK FOR
STANDARD RESIDENTIAL
FVIR GAS WATER HEATERS
MODELS: GCV, GCVH, GCVL, GVR, XCV, XCVL,
XGV, XVR - SERIES 200/201
GVRL, XVRL (40-Gallon Short) SERIES 202/203
06/09
316877-000

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the GCV Series and is the answer not in the manual?

Questions and answers

Related Manuals for A.O. Smith GCV Series

Summary of Contents for A.O. Smith GCV Series

  • Page 1 http://waterheatertimer.org/How-to-troubleshoot-gas-water-heater.html SERVICE HANDBOOK FOR STANDARD RESIDENTIAL FVIR GAS WATER HEATERS MODELS: GCV, GCVH, GCVL, GVR, XCV, XCVL, XGV, XVR - SERIES 200/201 GVRL, XVRL (40-Gallon Short) SERIES 202/203 06/09 316877-000...
  • Page 3 SERVICE HANDBOOK Your safety and the safety of others is extremely important in the servicing of this water heater. Many safety- related messages and instructions have been provided in this handbook and on your water heater to warn you and others of a potential hazard. Read and obey all safety messages and instructions throughout this handbook. It is very important that the meaning of each safety message is understood by you and others who service this water heater.
  • Page 4 Fire or Explosion Harzard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Avoid all ignition sources if you smell Natural or LP gas. Do not expose water heater control to excessive gas pressure.
  • Page 5 TROUBLESHOOTING QUICK REFERENCE IMPORTANT: Before performing any test, check the area around the water heater for any source of a flammable vapor (i.e gasoline, paint thinners, etc.) If any sources are found do not proceed until they are removed. PROBLEM POSSIBLE CAUSE TEST / CORRECTIVE ACTION NO HOT WATER:...
  • Page 6 PROBLEM POSSIBLE CAUSE TEST / CORRECTIVE ACTION WATER LEAKAGE: Thermostat does not shut-off Check the Gas Control Valve/Thermostat as described on p. 20-21. Drain valve dripping/leaking Back fl ush to clean- out sediment, replace if necessary Tank Leak Check Leakage Checkpoints described on p.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS BASIC INSTALLATION ............................8-16 DRAINING AND FILLING THE WATER HEATER ....................17 Draining the Water Heater ..........................17 Filling the Water Heater ............................17 CHECKING THE GAS SUPPLY FOR PRESSURE ....................18 CHECKING FOR SUFFICIENT COMBUSTION AIR OR VENTING ISSUES ..........18-19 Combustion Air Test ............................18 Draft Test ................................19 External Inspection &...

  • Page 8: Basic Installation

    BASIC INSTALLATION & OPERATION INSTALLATION OF RESIDENTIAL GAS WATER HEATER Water Supply- Cold* Water Exhaust Vent to Shut-Off Ouside of Building See Labels and Valve Installation Instructions *Massachusett: Install and Use & Care Guide a vacuum relief in cold Union for clearances.
  • Page 9 BASIC INSTALLATION & OPERATION This portion of this handbook applies to the Operations and Servicing of Residential Gas, Tank Type, Water Heaters, which are vented atmospherically and use a thermocouple as their electrical source. Control: There are two gas control valve/thermostat confi gurations available. Both valves have similar control elements such as the Gas Control Knob &...

  • Page 10: Normal Operation

    BASIC INSTALLATION & OPERATION Burner/Manifold Door Assembly: The burner/manifold assembly consists of several components such as: main burner, burner orifi ce, manifold tube, pilot burner, pilot orifi ce, pilot tube, igniter, and thermocouple. See the fi gure below for the complete list of components. The pilot burner remains on once it is manually lit.
  • Page 11 BASIC INSTALLATION & OPERATION Energy Cut Off (ECO): A metal tube (Temperature Figure 5 Probe) mounted onto the back of the gas control Gas Control Knob valve/thermostat is immersed inside the tank water. Reset Button The probe acts as a temperature high limit. If water gets excessively hot, an Energy Cut Off (ECO) switch within the probe opens, interrupting the small electrical Gas Inlet...
  • Page 12 BASIC INSTALLATION & OPERATION Thermostat Operation: Standard residential water heaters use mechanical thermostats. With a mechanical thermostat, a dial setting of 120° F may shut the burner down at a tank temperature between 110° and 130° F. The heater will consistently shut off at this same temperature. For this same reason, water temperature may drop 15°...
  • Page 13 BASIC INSTALLATION & OPERATION Combustion Air Requirements: Table 1: Minimum Square Typical Room WARNING BTUH Input Feet with with 8’ Ceiling 8’ Ceiling 30,000 9 x 21 Carbon Monoxide Warning 45,000 14 x 20 Water heater must be vented to outdoors. 60,000 15 x 25 Vent must be installed by a qualified technician using...
  • Page 14 BASIC INSTALLATION & OPERATION All Air from Inside the Building: When additional air Minimum Free Area of Permanent Openings for is to be provided to the confi ned area from additional Ventilation and Combustion Air Supply - All Air from room(s) within the building, the total volume of the Outdoors Only.
  • Page 15 BASIC INSTALLATION & OPERATION Vent Connectors: 1 SQ. INCH PER 1. Type B, Double wall, U.L. Listed Vent Pipe. 2000 BTUH 100 SQ. INCH 2. Single wall Vent Pipe. MINIMUM (EACH) Maintain the manufacturer’s specifi ed minimum clearance from combustible materials when using type OUTLET B double wall vent pipe.
  • Page 16 BASIC INSTALLATION & OPERATION The following fi gures are examples of vent pipe system • The connector must be firmly attached and sealed installations and may or may not be typical for your to prevent it from falling out. specifi c application. Consult the “National Fuel Gas •...

  • Page 17: Draining And Filling The Water Heater

    DRAINING AND FILLING THE WATER HEATER F illing the Water Heater D raining the Water Heater Never use this water heater unless it is completely full of water. To prevent damage, the tank must be fi lled with water. Water must fl ow from the hot water faucet before lighting the water heater.

  • Page 18: Checking The Gas Supply For Pressure

    CHECKING THE GAS SUPPLY PRESSURE Checking the Gas Supply Pressure GAS PRESSURE LABEL WHITE RODGERS GAS CONTROL Gas pressure checks are done with flowing gas using VALVE/THERMOSTAT SHOWN a gas pressure gauge capable of reading pressure in PRESSURE inches of water column. GAUGE CONNECTED AT •...

  • Page 19: Draft Test

    CHECKING FOR SUFFICIENT COMBUSTION AIR OR VENTING ISSUES Draft Test External Inspection & Cleaning of the Base-Ring Filter After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the draft 1. At least annually check the base-ring filter for any hood relief opening for proper draft.

  • Page 20: Testing The Thermocouple And Gas Control Valve/Thermostat

    TESTING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT IMPORTANT: Before performing any test, check the area around the water heater for any source of a Flammable Vapor (i.e gasoline, paint thinners, etc.) If any sources are found do not proceed until they are removed. Thermocouple Output Test The following test will check the DC voltage generated by the thermocouple when the pilot light is lit.

  • Page 21: Replacing The Thermocouple And Gas Control Valve/Thermostat

    REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT Removing the Manifold/Burner Assembly Removing the Burner from the Manifold/ Burner Assembly 1. Turn off the gas supply to the water heater at the manual gas shut-off valve. This valve is typically Natural Gas (Low Nox) & L.P. Gas Burner located beside the water heater.

  • Page 22: Replacing The Manifold/Burner Assembly

    REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT 5. Replace the two screws, which secure the manifold/burner assembly door to the combustion FERRULE NUT THERMOCOUPLE chamber and tighten securely. Once the manifold/ IGNITER WIRE burner assembly door is tightened, visually inspect PILOT PILOT BRACKET the door gasket between the manifold/burner...

  • Page 23: Removing And Replacing The Gas Control Valve/Thermostat

    REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT To remove the gas control valve/thermostat, thread CLOSE-UP INSIDE VIEW OF a correctly sized pipe into the inlet and use it to turn THE COMBUSTION CHAMBER. the gas control valve/thermostat (counterclockwise.) Do not use pipe wrench or equivalent to grip body. Damage may result, causing leaks.

  • Page 24: Adjusting The Temperature On The Gas Control Valve/Thermostat

    ADJUSTING THE TEMPERATURE ON THE GAS CONTROL VALVE THERMOSTAT reset to the desired temperature setting to reduce Water temperature over 125°F (52°C) the risk of scald injury. The index bar (Robsertshaw) can cause servere burns instantly mark (White-Rodgers®) are indicative of resulting in severe injury or death.

  • Page 25: Gas Water Heater Sizing Guide

    GAS WATER HEATER SIZING GUIDE Use the following information as a guide to approximate the correct size water heater for the residence: • 30 gallon size (21 gallon draw) for one bath residence. • 40 gallon size (28 gallon draw) for two bath residence -or one bath with an automatic clothes washer. •...

  • Page 26: Technical Service Bulletins

    TECHNICAL BULLETINS WATER HAMMER ..............................27 MINERAL BUILD-UP ..............................28 ALUMINUM HYDROXIDE ............................29 CONDENSATION ..............................30 DISCOLORED WATER ............................31 SMELLY WATER ..............................32 CHLORINATION PROCEDURE ..........................33 NOT ENOUGH HOT WATER ..........................34 THERMAL EXPANSION ........................... 35-36 LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE ................37 INSULATION BLANKETS ............................38...

  • Page 27: Water Hammer

    BULLETIN 11 WATER HAMMER GENERAL Water hammer is the destructive force, pounding noise and vibration in a piping system when water fl owing through a pipeline is stopped abruptly. When water hammer occurs, a high intensity pressure wave travels back through the piping system until it reaches a point of some relief.

  • Page 28: Mineral Buildup

    BULLETIN 13 MINERAL BUILD-UP SYMPTOMS • Rumbling • Crackling • Popping CAUSE With the increase in fuel costs and hot water consumption, deliming has become a necessity of modern maintenance. Lime (CaCO3), is the most notable factor when discussing water hardness. Lime is present in every water system to some degree. Since lime is inversely soluble [the more you heat, the more lime comes out], higher usage, excessive hardness, and increased heating surface can lead to a high incidence of “limed-up”...

  • Page 29: Aluminum Hydroxide

    BULLETIN 14 ALUMINUM HYDROXIDE SYMPTOMS “Crackling”, “gurgling”, or “popping” noises from new water heaters (installed less than six months). CAUSE In a few isolated parts of the United States where the water supply has a relatively high pH (8+), water conditions will react with the aluminum anode to form excessive amounts of aluminum hydroxide on the anode and in the bottom of the tank.

  • Page 30: Condensation

    BULLETIN 15 CONDENSATION SYMPTOMS The water heater appears to be releasing water while the main burner is on or water is found surrounding the heater shortly after the water heater has been used. This bulletin explains why fl ue gases condense and how you can differentiate between condensation and leaking.

  • Page 31: Discolored Water

    BULLETIN 21 DISCOLORED WATER SYMPTOMS Rusty, brown, black, or yellow water appearing in the hot water. CAUSES Complaints of discolored water are commonly blamed on water heaters and storage tanks, but in fact, it is a rare occurrence for today’s high quality glass lined tanks to have a lining failure signifi...

  • Page 32: Smelly Water

    BULLETIN 22 SMELLY WATER CAUSES The most common cause of “smelly water” is a non-toxic sulfate reducing bacteria, scientifi cally termed Divibrio Sulfurcans. This bacteria often enters the water system through construction or a break in ground piping. The bacteria creates the energy it needs to survive by converting sulfate (SO4) to hydrogen sulfi...

  • Page 33: Chlorination Procedure

    BULLETIN 23 CHLORINATION PROCEDURE CAUSES The chlorination procedure is used to eliminate various bacteria that accumulate and grow in water heaters. These bacteria often cause odorous or discolored water conditions. PROCEDURE Please read the steps of the chlorination procedure prior to beginning. If you feel uncomfortable performing any of these steps, contact a service person to perform this procedure for you.

  • Page 34: Not Enough Hot Water

    BULLETIN 35 NOT ENOUGH HOT WATER - GAS CAUSES Complaints regarding an insuffi cient supply of hot water are typically the result of a water heater that cannot meet the demands of the residence (both people and appliances). The demand for suffi cient hot water may also be exceeded if additional people and/or appliances are added to the residence.

  • Page 35: Thermal Expansion

    BULLETIN 45 THERMAL EXPANSION SYMPTOMS • Effects are only noticeable after hot water use followed by periods of no water use. • Relief valve drips during any recovery cycle when no hot or cold water is used. • Hot water pipes creak while heater is recovering and all valves are closed. •...

  • Page 36: Thermal Expansion

    THERMAL EXPANSION THE FIX The ideal fi x involves the use of a pressure reducing valve if supply pressures are above 60 to 70 psi, and a properly sized expansion tank. The PRV reduces supply pressures to 40 to 60 psi allowing an economically priced and sized expansion tank to be used.

  • Page 37: Leaking Temperature And Pressure Relief Valve

    BULLETIN 52 LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE SYMPTOMS • Water seeping around the relief valve tank connection • Leakage at the threaded portion of the relief valve connection • Intermittent weeping and/or dribbling from the relief valve • Large volume of hot water sporadically discharged from the relief valve GENERAL The temperature and pressure relief valve (T &...

  • Page 38: Insulation Blanket

    BULLETIN 60 INSULATION BLANKETS GENERAL The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Most modern water heaters have adequate factory installed insulation, the use of an after market insulation blanket is no longer recommended by most experts. While the use of an external insulation blanket will not void the warranty, the water heater manufacturer explicitly disclaims any liability for problems associated with the use of insulation blankets.

  • Page 39: General Information

    GENERAL INFORMATION Draw efficiency is the quantity of hot water available to the consumer before the outlet water temperature decreases 25 degrees F. A 40 gallon water heater will typically provide 70% (28 gallons) of this “usable” hot water (60% is the minimum). The burner or elements are allowed to operate during this test. Incoming, cold water mixes the remaining stored water below this 25 degree limitation.
  • Page 40 GENERAL INFORMATION One pound of gas pressure is equal to 27.7 inches water column pressure Inches of Water Column X .036091 = PSI Inches of Water Column X .073483 = Inches of Mercury (Hg.) Centimeters = Inches X 2.54 MM (millimeters) =Inches X 25.4 Meters = Inches X .0254 Doubling the diameter of a pipe will increase its flow capacity (approximately) 5.3 times.
  • Page 41 NOTES...
  • Page 42 NOTES...
  • Page 44 ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CONTACT A O SMITH WATER HEATERS RESIDENTIAL TECHNICAL ASSISTANCE AT 1-800-527-1953 OR WWW.HOTWATER.COM.

This manual is also suitable for:

Gvr seriesXcv seriesXcvlseriesGcvh seriesXgv seriesXvr series ... Show all

Table of Contents

Save PDF